Folding Chair Armrest with Integrated Cup Holder

ABSTRACT

An armrest assembly for use on a folding chair. The armrest assembly has a molded plastic body with a top surface upon which a person&#39;s arm rests. The molded plastic body has an underside that is reinforced by support ribs for strength. The molded plastic body of the armrest assembly is molded in two parts. A first body section is molded of a first material and a second body section is molded of a second material. The first material is a rigid plastic material. The second material is a flexible plastic material. The second body section of flexible plastic material is overmolded onto the first body section of the rigid plastic material. A cup holder construct is formed into the armrest assembly. The cup holder construct is formed in part of the rigid plastic material and in part by the flexible plastic material.

BACKGROUND OF THE INVENTION 1. Field of the Invention

In general, the present invention relates to the structure of the armrests that are used on folding chairs, collapsible chairs, camp chairs, beach chairs and other portable lightweight chairs. More particularly, the present invention relates to armrests that contain cop holders within the structure of the armrests.

2. Prior Art Description

There exist many different styles and models of collapsible chairs that are intended to be carried by a user. In addition to be being foldable or collapsible, such chairs are made to be as lightweight as possible while still being functionally sound. In this manner, the chair is not burdensome to carry.

Such chairs are often brought to the beach, to tailgates, to concerts and to other such locations that require a chair to be carried a significant distance.

In order to make a chair lightweight, a folding chair is typically manufactured with minimalistic armrests. Often the armrests are little more than strips of fabric or thin moldings of lightweight plastic. The armrests are strong enough to support the weight of an arm, however, the armrests have little integrity to serve any other purpose. Auxiliary items, such as cup holders and cell phone pockets are simply attached to some reinforced part of the armrest or to the support frame under the armrest. Such prior art armrests are exemplified by U.S. Patent Application Publication No. 2003/0193222 to Welsh.

When a cup holder is attached to an armrest in an automobile or to an armrest in a movie theater seat, there is enough mass of material to integrate the cup holder into the central structure of the armrest. This is typically done by providing a cylindrical depression into the structure of the armrest that is large enough to receive a can, cup or bottle of an average diameter. Such prior art is exemplified by U.S. Pat. No. 5,150,946 to Marfilius and U.S. Pat. No. 7,614,703 to Bergin. However, in a portable beach chair, the material available at the armrest is so thin that it makes the formation of a cup holder impractical. Furthermore, due to the scarcity of material and support, any cup holder that can be formed is little more than a hole in the material of the armrest. The cup holder does not have any specialized features, such as a tightening mechanism, that can close around small diameter cans, cups, and bottles.

A need therefore exists for an armrest design for a lightweight folding chair that incorporates a cup holder, wherein the cup holder is structurally sound and has the ability to retain a wide variety of cans, cups and bottles without adding significantly to the weight or cost of the armrest. This need is met by the present invention as described and claimed below.

SUMMARY OF THE INVENTION

The present invention is an armrest assembly for use on a lightweight folding chair or collapsible chair. The armrest assembly has a molded plastic body with a top surface upon which a person's arm rests.

The molded plastic body has an underside that is reinforced by support ribs for strength. The molded plastic body of the armrest assembly is molded in two parts. A first body section is molded of a first material and a second body section is molded of a second material. The first material is a rigid plastic material that provides the armrest assembly with strength and structural integrity. The second material is a flexible plastic material, such as a thermoplastic rubber. The second body section of flexible plastic material is overmolded onto the first body section of the rigid plastic material.

A cup holder construct is formed into the armrest assembly. The cup holder construct is formed within part of the rigid plastic material of the first body section and within part of the flexible plastic material of said second body section.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference is made to the following description of an exemplary embodiment thereof, considered in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of an exemplary embodiment of an armrest assembly with a cup holder construct;

FIG. 2 is a bottom view of the exemplary embodiment of the armrest assembly shown with the cup holder construct;

FIG. 3 is an enlarged view of the cup holder construct;

FIG. 4 is an exploded view of the exemplary embodiment of FIG. 3.

DETAILED DESCRIPTION OF THE DRAWINGS

Although the present invention armrest assembly can be adapted for use in many styles and models of folding chairs, the armrest assembly is shown in only one example. The exemplary embodiment is selected in order to set forth one of the best modes contemplated for the invention. The illustrated embodiment, however, is merely exemplary and should not be considered a limitation when interpreting the scope of the appended claims.

Referring to FIG. 1 in conjunction with FIG. 2 and FIG. 3, an armrest assembly 10 is shown that can be used on a folding chair 11. The armrest assembly 10 includes a two-part plastic body 12, which includes a first body section 14 and a second body section 16. The first body section 14 and the second body section 16 are molded from two separate plastic materials. The first body section 14 is molded from a hard plastic, such as PVC. The second body section 16 of the two-part plastic body 12 is molded from a soft, flexible elastomeric plastic, such as thermoplastic rubber (TPR).

When complete, the two-part plastic body 12 has a generally planar top surface 18 and a peripheral side wall 20 that extends downwardly from the edges of the top surface 18. When positioned in an unfolded chair, the top surface 18 of the two-part plastic body 12 is generally positioned in a horizontal plane and the surfaces of the peripheral side wall 20 are generally oriented in the vertical. In use, a person's arm and/or hand rests upon the top surface 18 of the two-part plastic body 12. The top surface 18 is generally smooth with the exception of the entrance opening to a cup holder construct 24 being accessible from the top surface 18.

The first body section 14 of the two-part plastic body 12 and the second body section 16 of the two-part plastic body 12 are both exposed on the top surface 18 of the two-part plastic body 12. The elastomeric material of the second body section 16 is over-molded onto the first body section 14. The first body section 14 of the two-part plastic body 12 is the primary structure of the two-part plastic body 12 and provides the two-part plastic body 12 with its structural strength. The first body section 14 of the two-part plastic body 12 has a first end 26 and an opposite second end 28. The first end 26 of the first body section 14 attaches to the backrest framing 29 of the folding chair 11. The first body section 14 of the two-part plastic body 12 is not solid. Rather, to minimize material, weight, and expense, the first body section 14 is molded to be mostly hollow. The first body section 14 of the two-part plastic body 12 does not have a smooth bottom surface. Rather, below the top surface 18 is a complex underside 30. The underside 30 consists of a series of molded reinforcement ribs 32 within the confines of the peripheral side wall 20. The reinforcement ribs 32 provide structural integrity and strength to the first body section 14 of the two-part plastic body 12.

Referring to FIG. 3 and FIG. 4, in conjunction with FIG. 1 and FIG. 2, it can be seen that the cup holder construct 24 has a lower segment 34 and an upper segment 36. The lower segment 34 is molded as part of the first body section 14 in the hard plastic material of the first body section 14. The upper segment 36 is molded as part of the second body section 16 in the elastomeric material of the second body section 16.

The lower segment 34 of the cup holder construct 24 is molded as a receptacle 25 that is large enough to receive a cup, can or bottle that is larger than the average size. The receptacle 25 has a horizontal base 38 that is suspended between side walls 40. The side walls 40 can be custom molded or can ce formed by the reinforcement ribs 32. The side walls 40 are vertical or diverge slightly from vertical. The base 38 can be either solid of perforated to allow for drainage. Likewise, the side walls 40 can be solid or can contain various openings 42 to reduce mass and provide for drainage.

The upper segment 36 of the cup holder construct 24 has a ring structure 44 that concentrically aligns over the receptacle 25. The ring structure 44 has an inside diameter D1 that is large enough to accommodate oversized cups, bottles and cans. In order to prevent movement of cups, cans and bottles that are average sized or undersized, a plurality of flexible tabs 46 are molded as part of the ring structure 44. The flexible tabs 46 are symmetrically positioned around the ring structure 44 and extend inwardly toward a common center point in a common plane. In the shown embodiment, four flexible tabs 46 are illustrated. This is exemplary, and it will be understood that any plurality of flexible tabs 46 can be used. The ring structure 44 has an inner diameter D1. Each of the flexible tabs 46 gas a length L1 that is at least 20 percent of the diameter D1 of the the ring structure 44. In this manner, the open area 48 between the various flexible tabs 46 is significantly smaller than the diameter D1 of the ring structure 44. Preferably, the open area 48 between the flexible tabs 46 is smaller than the average sized can, cup or bottle. The flexible tabs 46 are molded from the same elastomeric material as is the remainder of the second body section 16. As such, the flexible tabs 46 will bend when contacted with a cup, can or bottle. If a smaller than average cup, can, or bottle is placed in the cup holder construct 24, the flexible tabs 46 may not be contacted or may just bend a small amount. If a larger than normal cup, can or bottle is placed into the cup holder construct 24, then the flexible tabs 46 will bend significantly. In either scenario, the flexible tabs 46 prevent a cup, can or bottle from tilting within the confines of the cup holder construct 24.

Referring to FIG. 3 and FIG. 4, it can be seen that the elastomeric material of the second body section 16 is overmolded onto the first body section 14 of hard plastic. To accommodate the overmolding process, a relief 50 is formed in the first body section 14 of the two-part plastic body 12 that corresponds to the size and shape of the second body section 16. In this manner, when the second body section 16 is molded onto the first body section 14, the top and sides of the two-part plastic body 12 remain smooth and flush across the transitions lines between body sections 14, 16.

The armrest assembly 10 may be exposed to large variations in temperature and humidity over its working life. Since the armrest assembly 10 is made of two different plastics, the first body section 14 and the second body section 16 may react slightly differently to the changes in temperature and humidity. To prevent any chance of plastic separation, locking elements 52 are molded into the two-part plastic body 12. The locking elements 52 can have a variety of forms. In the shown embodiment, a plurality of fins 54 are molded into the first body section 14 within the relief 50. The fins 54 are arranged in a tight formation so that narrow gaps 56 separate the various fins 54. When the elastomeric material of the second body section 16 is molded over the first body section 14, the elastomeric material of the second body section 16 fills the gaps 56 between the various fins 54. The fins 54 appear as decorative elements on the final armrest assembly 10. However, the primary purpose of the fins 54 is to create a mechanical interlock between the material of the first body section 14 and the material of the second body section 16.

It will be understood that the embodiment of the present invention that is illustrated and described is merely exemplary and that a person skilled in the art can make many variations to that embodiment. For instance, the present invention can be adapted to most any plastic armrest used on folding or collapsible chairs. All such embodiments are intended to be included within the scope of the present invention as defined by the claims. 

What is claimed is:
 1. An armrest assembly for a folding chair, comprising: a molded two-part plastic body having a first body section of a first material and a second body section of a second material, wherein said second body section is overmolded onto said first body section; and a cup holder construct formed into said armrest assembly, wherein said cup holder construct is formed in part of said first material of said first body section and in part by said second material of said second body section.
 2. The armrest assembly according to claim 1, wherein said first material is a rigid plastic and said second material is an elastomeric plastic.
 3. The armrest assembly according to claim 1, wherein said cup holder construct has a ring structure that defines an opening, and an underlying receptacle, wherein said ring structure is part of said second body section and said receptacle is part of said first body section.
 4. The armrest assembly according to claim 3, further including a plurality of tabs that extend inwardly from said ring structure.
 5. The armrest assembly according to claim 4, wherein said plurality of tabs are integrally molded as part of said ring structure from said second material.
 6. The armrest assembly according to claim 4, wherein said ring structure has an inside diameter and each of said plurality of tabs extends inwardly from said ring structure by a distance at least as great as twenty percent of said inside diameter.
 7. The armrest assembly according to claim 1, further including a relief formed into said first body section of said molded two-part plastic body, wherein said second body section is overmolded onto said first body section within said relief.
 8. The armrest assembly according to claim 7, further including locking fins that extend from said first body section within said relief, wherein said second material of said second body section molds around said locking fins, therein creating a mechanical interconnection between said first body section and said second body section.
 9. An armrest assembly for a folding chair, comprising: a first body section molded of a rigid material; a second body section molded of a flexible material, wherein said second body section is overmolded onto said first body section; and a cup holder construct formed into said armrest assembly, wherein said cup holder construct has an open top and a base, wherein said open top of said cup holder construct is part of said second body section and said base of said cup holder construct is part of said first body section.
 10. The armrest assembly according to claim 9, wherein said flexible material is a thermoplastic rubber.
 11. The armrest assembly according to claim 9, wherein said open top of said cup holder construct is defined by a ring structure, wherein said ring structure is part of said second body section.
 12. The armrest assembly according to claim 11, further including a plurality of tabs that extend inwardly from said ring structure.
 13. The armrest assembly according to claim 12, wherein said plurality of tabs are integrally molded as part of said ring structure from said flexible material.
 14. The armrest assembly according to claim 12, wherein said ring structure has an inside diameter and each of said plurality of tabs extends inwardly from said ring structure by a distance at least as great as twenty percent of said inside diameter.
 15. The armrest assembly according to claim 9, further including a relief formed into said first body section, wherein said second body section is overmolded onto said first body section within said relief.
 16. The armrest assembly according to claim 15, further including locking fins that extend from said first body section within said relief, wherein said flexible material of said second body section molds around said locking fins, therein creating a mechanical interconnection between said first body section and said second body section. 